Document xzqmnkkNQJ7EXB6z0Mw4BQKNQ

FILE NAME: Sprayed Asbestos (SPRA) DATE: 1971 DOC#: SPRA023 DOCUMENT DESCRIPTION: US Patent United States latent [72] Inventors John Denis Pennington Bolton; William Ian Hay Winning, Yarm-on-Tees, both of England [21] Appl. No. 717.418 [22] Filed Mar. 29,1948 [45] Patented Nov. 23,1971 [73] Assignee Tac Construction Materials Ltd. [32] Priority Mar. 29,1967 [33] Great Britain [31] 14,318/67 [54] PRODUCTION OF INSULATING COATINGS BY SPRAYING 8 Claims, No Drawings [52] U.S.CI......................................................... 106/93, 106/90,106/99,106/105, 106/104,106/108, 106/115,106/119,106/15 FP, 161/403,252/8.1 [51] Int.CL......................................................... C04b31/06, C04b 31/44 [50] Field of Search............................................. 106/99,97, 93,90,107,108, 111, 115,81,84, 104;252/8.l, 463; 161/403 nu 3,622,361 [56] References Cited UNITED STATES PATENTS 3,242,986 3,093,505 2,815,293 2,644,771 2,633,433 2,509,599 2,438,339 1,920,358 1,851,038 803,285 3/1966 6/1963 12/1957 7/1953 3/1953 5/1950 3/1948 8/1933 3/1932 10/1905 Hower............................ Conway......................... Randalletal.................. Kempthome................. Hollenberg.................... Hollenberg.................... Jacobs........................... Clark............................. Clark............................. Hayde........................... 106/90 106/90 106/97 106/99 252/62 106/99 161/163 106/99 106/285 106/99 Primary Examiner--James E. Poer Assistant Examiner--W. T. Scott Attorney--Sughrue, Rotliwell, Mion, Zinn & Macpeak ABSTRACT: Compositions for forming insulating coatings by spraying mineral wool and fiber, cement or other binder and water are based on mineral wool, and include mineral oil and a surface-active agent or a cellulose ether. F 3,622,361 l PRODUCTION OF INSULATING COATINGS BY SPRAYING The production of coatings or. surfaces for the purpose of thermal or acoustic insulation or fire protection by spraying asbestos fiber and a binder is well known. Our object in this in vention is to reduce the cost by replacing asbestos by mineral wool. ` Mineral wool has indeed been used in admixture with with the water, but preferably is included in the composition with the mineral wool, Under and mineral oil, Either the sur face-active sgsnt or tne cellulose ether can be added as a powder during the mixing ieft.red to above or to the remain ing constituents of the composition immediately before the sprayirg. However, it ir, preferred io introduce the surface-ac tive agent or cc.luiose ether at an earlier stage in the prepara tion of the composition, namely by spraying it within a a--s-b--e-s--to--s, but it has not ihii.tuhieviiituo ubcecen ifceasiobile to use it as tnhe chamber m wihniech the mineral wool fibers are being made sole fibrous component of the sprayed coating. The reason is 10 fiom slag or rock. ttnhiai tt mi i i ineral1 .w11oo. lI dd.o-vesI- _noat possess athL e. vhigh capi-llarit. y ofa The T 'Lftft pro^ porti!ons of the composition may vary widely but asbestos fiber and therefore does not conere at the time when preferably are as follows in percent by weight: the coating is being formed. Some of the sprayed material falls to the ground. binder 10 to 4 0 * In the spraying of any fiber to form an insulating coating it is 15 necessary also to spray a binder or the constituents of a binder. The binder commonly used in the spraying of asbestos m in e ra l ol surface* active agent o r cellulose 0 25 to 3 0 * is cement, which is premixed with the asbestos and caused to set by water sprayed simultaneously. However, cement or any ether or both m ineral wool 0 0 1 to 3.0 * the rem ainder other powder binder does not adhere well to mineral wool, 20 with the result that some of the binder is lost at the time of n p le o f p roportions is as % spraying and does not serve its purpose, and there is also a considerable amount of visible dust in the spray. It is of course important to prevent the production of dust, which is un pleasant to the operator and anyone else in the vicinity. 25 m ineral woo) Portland-cem ent m ineral oil sodium salts of 78 3 5 * 20* 1 5* In forming a coating by spraying fiber, a powder binder and alkylated naphtha water onto a surface according to this invention, the fiber is laecnide.sulfonic 0 1 5 * mineral wool and the spray includes a mineral oil and a sur face-active agent or a cellulose ether or both. We find that by' the introduction of the oil and the surface-active agent or cel 30 lulose ether the presence of visible dust in the spray can be vir tually eliminated, tne cohesion at the time of spraying is adequate to prevent the sprayed material from falling to the ground, and the adhesion of the sprayed coating to the surface is good. 35 Mineral wool may be produced from metallurgical slag or from rock, and either kind may be used in the invention. Whatever its origin, the main chemical constituents in per centage by weight are from 25 to 50 peiccnt S:0,, ? to 20 per cent AlgOj, 20 to 45 percent CaO and 3 to 18 percent MgO. 40 The individual fibers commonly are from 2 to 10 microns in diameter and up to 1 inch in length, though the average length is from one-eighth to one-fourth inch. In the mixture which is sprayed the mineral wool is preferably present as tufts from We claim: ' 1. A sprayable, settable composition for use in forming a coating upon being set by water consisting essentially of from 10 to 40 percent of an inorganic, water-settable powder binder selected from the group consisting of Portland cement, ciment fondu, a mixture of Portland cement and ciment fon- du, magnesium oxychloride, magnesium oxysulfate, lime, gyp sum and clay, from 0.25 to 3 percent of a mineral oil and from 0.01 to 3 percent of at least one compound selected from the group consisting of anionic surface-active agents, nonionic surface-active agents and cellulose ethers, the balance of said composition being mineral wool tufts, all percents being by weight, said composition yielding substantially no visible dust upon spraying and providing good cohesion prior to the setting of said binder and good adhesion to the surface upon which it is coated. ' three-eighths to three-fourths inch long. 45 2. A composition according to claim 1 in which the binder is The binder is preferably Portland cement or ciment fondu Portland cement. or a mixture of these, but may be based on magnesium ox 3. The composition of claim 1 wherein said surface active ychloride. magnesium oxysulfate, line, gypsum, clay, sodium agent is selected from the group consisting of the sodium salts silicate or potassium silicate. The mineral oil is preferably a of alkylated naphthalene sulfonic acid, the condensation clear fine oil. The surface-active agent is preferably nonionic 50 products of alkyl phenol and ethylene oxide, and the an or anionic, and we find that the best agents for the purpose are hydrous condensation products of a long-chain fatty alcohol the sodium salts of alkylated naphthalene sulfonic acid; the and ethylene oxide. . condensation products of alkyl phenol and ethylene oxide; 4. The composition of claim 1 wherein said one compound and anhydrous condensation products of a long-chain fatty al is a cellulose ether. cohol and ethylene oxide. Of the cellulose ethers methyl 55 5. The composition of claim 4 wherein said cellulose ether is hydroxypropyl cellulose is particularly suitable. methylhydroxypropyl cellulose. The invention includes as a novel composition for use in a ^ 6. The composition of claim 1 wherein said one compound spraying process the mixture of mineral wool, binder and is a surface-active agent. mineral oil. In prep arinV g this co-mTpo---s---iltilito*n1,11t1h11eVIm<11inUeIIrallilctojfil may 7. In t* h* e*p^frteV^ p/aM rIaUtU ioW nII V o*f a V coW mlltppousaiiltU ioJIni 0a4s cltadillmtlCevdJ iin n C clid aiim m 11,, advantageously be introduced into a mixture of the mineral 60 the steP of introducing the mineral oil by spraying onto a mix- wool and binder by spraying either into a drum mixer in which ture f the mineral wool and binder. the mineral wool and binder are mixed or into a feeder to * ln the preparation of a composition as claimed in claim 1 which the mineral wool and binder are continuously fed an d ' the s|eps of producing mineral wool fibers from slag or rock so mixed ir, appropriate proportions. In either case the mix- and introducing at least one compound selected from the ture m-a,yv adHvannhtaTMgeTMou.s,liy,, bke- passed-1 t*h*r-o--u-g- *h- --an o--p-e--n-ing 65 group consisting of surface-active agents s ,d cellulose ethers machine having rotating blades to break down the mass of wool into tufts and to increase the uniformity of the mixture. into the mineral wool by spraying during the production of said fibers. The surface-active agent or cellulose ether can be sprayed 70 75